US4043825A - Production of foamed gypsum moldings - Google Patents

Production of foamed gypsum moldings Download PDF

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Publication number
US4043825A
US4043825A US05/604,868 US60486875A US4043825A US 4043825 A US4043825 A US 4043825A US 60486875 A US60486875 A US 60486875A US 4043825 A US4043825 A US 4043825A
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United States
Prior art keywords
acid
alkali
gypsum
reacting compound
mixture
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Expired - Lifetime
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US05/604,868
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English (en)
Inventor
Martin Muller
Friedrich Hinsche
Gerhard Winter
Karl Brandle
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Bayer AG
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Bayer AG
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements

Definitions

  • This invention relates to a process for the production of porous bodies based on gypsum, more especially anhydrite, by liberating oxygen from hydrogen peroxide in an alkaline binder suspension.
  • the suspension is cast, foams slowly and uniformly and sets with the pore structure intact.
  • the foaming of aqueous suspensions of calcium sulfate semihydrate, which is known as plaster of Paris, or of anhydrous calcium sulfate, known as anhydrite, is known in principle.
  • a gypsum pulp and an aqueous foam, prepared separately therefrom to obtain a mass permeated by air bubbles which sets with the pore structure substantially intact.
  • the disadvantages of this process include the partial collapse of the pore structure when the two components are mixed, and the fact that the process can only be carried out in batches because the foamed mass can only be conveyed with further collapse of the pore structure.
  • a gas is produced in the pulp by a chemical reaction, the required pore structure subsequently being formed by this gas. It is preferred to produce carbon dioxide as the blowing gas by reacting carbonates with acids or acid-reacting salts such as, for example, aluminum sulfate. Naturally, these processes are carried out in an acid medium at a pH value below 7 (German DAS 1,300,459 and 1,571,575).
  • a foaming wetting agent is used to promote foam formation, preferably during the separate production of an aqueous foam (Austrian Pat. No. 176,493).
  • a gypsum pulp containing an addition of, for example, an alpha-olefin sulfate.
  • this wetting agent is used, the effect obtained is only minimal because the density of the porous gypsum thus produced is only slightly different from the value obtained taking into account the evaporated excess of water.
  • the use of a wetting agent in the gypsum pulp is obviously not sufficient for the production of a stable foam.
  • the object of the present invention is to provide porous bodies based on gypsum and a process for their production, in which the requirements referred to above are satisfied and the disadvantages of conventional processes are overcome. More specifically, the object of the invention is to provide porous bodies in which the formation and setting of a foamed mass can be strictly co-ordinated with one another in terms of time.
  • the expression "gypsum” is used for completely and partly dehydrated calcium sulfate hydrates which have the property of setting in the presence of water.
  • the expression gypsum covers, for example, the semihydrate CaSO 4 .1/2 H 2 O, plaster of Paris, and also the anhydrous forms CaSO 4 , screened gypsum and the synthetic and natural anhydrite.
  • Plaster of Paris normally contains somewhat less water than the so-called semihydrate, although it is also known as semihydrate.
  • the expression “semihydrate” is used as a generic expression and includes plaster of Paris (cf. in this connection the nomenclature laid down in DIN 1168 and DIN 4208).
  • this object is achieved by adding acid compounds containing active hydrogen atoms to the mixture of anhydrite and/or gypsum containing alkaline constituents.
  • acid compounds containing active hydrogen atoms to the mixture of anhydrite and/or gypsum containing alkaline constituents.
  • the invention relates to a process for the production of porous bodies based on gypsum with high strength and a uniform pore structure by foaming a gypsum-water mixture, to which diluents, fillers, dyes, wetting agents and/or additives for influencing setting and flow properties may optionally be added, by the catalytic decompositions of hydrogen peroxide or its compounds, distinguished by the fact that gypsum and/or anhydrite containing alkaline constituents is suspended in an aqueous solution in the presence of hydrogen peroxide, brought into any form and foamed, the aqueous solution containing water-soluble acid compounds with active hydrogen atoms in a quantity which is not sufficient for complete neutralization.
  • the acid compounds should preferably be added in such a quantity that the suspension has a final pH-value in the range of from about 10 to 13.
  • water-soluble monohydrogen and dihydrogen phosphates optionally with an addition of water-soluble hydrogen sulfates.
  • the mixture should show an alkaline reaction in aqueous suspension.
  • Synthetic anhydrite normally contains about 0.3 to 3% of calcium oxide or an equivalent quantity of calcium hydroxide.
  • basic constituents are added.
  • the calcium sulfate material should contain at least 0.1% of CaO or an equivalent quantity of corresponding bases such as, for example, Ca(OH) 2 .
  • This proportion is highly variable, the only requirement being that the mixture to be foamed should have a pH-value of about 10 to 13, preferably about 12 to 12.5, in aqueous suspension.
  • MgO or Mg(OH) 2 may also be used as the basic constituent.
  • the mixture to be foamed may be thoroughly suspended in conventional mixers.
  • the liquid mixture is introduced as required into a mold to be filled with foam and begins to grow slowly after the particular time interval adjusted. Growth may last from 30 to 60 minutes. Thereafter the foamed mass is still fluid and begins to set with its volume and pore structure intact.
  • the pH-development of the suspension into the alkaline range is preferably extended to a period determined both by the mixing conditions and by the dimensions of the mold to be filled.
  • the process may be carried out either continuously or in batches.
  • an aqueous solution containing the active substances in accordance with the invention is preferably introduced initially, the binder is stirred in and the whole is thoroughly mixed.
  • the hydrogen peroxide solution may be added at any stage or even to the aqueous solution.
  • the aqueous solution and the binder mixture are continuously combined and mixed.
  • the suspension is then run off continuously and introduced into the mold to be filled.
  • Acid compounds suitable for use in the process according to the invention are, above all, monohydrogen and dihydrogen phosphates.
  • Suitable phosphates are, for example, monohydrogen and dihydrogen phosphates of the elements of the first to third Group of the Periodic System, such as for example KH 2 PO 4 , K 2 HPO 4 , NaH 2 PO 4 , Na 2 HPO 4 and Ca(H 2 PO 4 ) 2 .
  • Ammonium hydrogen phosphates, aluminum hydrogen phosphates such as, for example, Al[H 2 (PO 4 )] 3 are suitable, as are acids of phosphorus.
  • the monohydrogen and dihydrogen phosphates are preferably used.
  • Acid sulfates for example NaHSO 4 or KHSO 4 , may also be used together with the phosphates.
  • the substances active in accordance with the invention are used in a quantity which is not sufficient for completely neutralizing the alkaline constituents present in the anhydrite-gypsum material.
  • the possible degree of neutralization amounts to between about 2 and 60% and preferably to between about 5 and 50%.
  • the aqueous suspension should reach a pH-value of from about 10 to 13, preferably around 12.
  • Suitable catalysts are, above all, manganese compounds, for example manganese sulfate and manganese chloride.
  • Manganese compounds soluble in the alkaline medium for example manganates and permanganates, are particularly effective.
  • the catalysts may be added to the gypsum in solid form, although they are preferably added to the gypsum suspension in the form of an aqueous solution.
  • the catalysts are thoroughly mixed with the material in order to guarantee uniform evolution of oxygen.
  • the quantities used are governed by the effectiveness of the particular catalyst. For example, about 0.1 to 0.5 part of KMnO 4 are added to about 100 parts of gypsum. 0.3 part of KMnO 4 , about 1 part of MnSO 4 or MnCl 2 or 3 parts of manganese dioxide are equally effective.
  • the flow properties may be influenced by the addition of so-called plasticizers such as, for example, modified melamine resins, cellulose ethers, etc.
  • wetting agent based on 100 parts of the dry mixture.
  • Wetting agents based on alkyl sulfonates are particularly suitable.
  • the gypsum is used in the form of completely or partly dehydrated calcium sulfates which set in the presence of water, i.e. for example semihydrate or plaster of Paris or synthetic or natural anhydrite.
  • Synthetic anhydrite is formed, for example, in large quantities in the production of hydrofluoric acid from fluorspar and sulfuric acid where it accumulates in the form of so-called cinders.
  • mixtures of semihydrate and anhydrite in any ration. It is preferred to use mixtures containing up to about 50% of semihydrate, anhydrite-semihydrate mixtures containing about 10 to 40% of semihydrate plaster of Paris for adjusting their setting properties being particularly suitable.
  • additives such as sand, calcium sulfate dihydrate, expanded clay, pumice, cork, plastic granulate, glass fibers, glass wool, mineral wool, organic fibers, foamed glass particles and also pigments.
  • additives should be system-compatible, i.e. substantially alkali-resistant. It is also possible to add auxiliaries which influence setting behavior such as, for example, activators or retarders, such as for example carboxymethyl cellulose. Masses with a plasticizing or thickening effect, i.e. masses which influence the processibility and the pore structure of the foamed mass, may be added to the gypsum suspension. Suitable masses of this kind are organic and inorganic additives, for example styrene- or formaldehyde-containing polymers and condensates, especially with sulfonated groups, and also sols containing colloidal silica as plasticizers.
  • Suitable thickeners are, for example, cellulose derivatives or inorganic compounds based on clay.
  • plasticizers and thickeners In addition to the possibility of obtaining an increase in the strength of the products by using plasticizers because of the water saved, it is possible to use plasticizers and thickeners, more especially from the point of view of processing. Thus, plasticizers enable complicated molds to be completely and properly filled, while thickeners are able for example to reduce the requirements on the imperviousness of formwork.
  • Coloring is possible by the addition of dyes or pigments, for exammple to the suspension (homogeneous coloring or by appropriate aftertreatment.
  • Hydrophobizing and increasing water resistance for example on the basis of silicone oils, may be obtained by additions to the suspension or by appropriate aftertreatment.
  • foam stabilizers Although it is not essential to use surface-active substances as foam stabilizers for carrying out the process, it can be advantageous to use such stabilizers in cases where the foaming of foamed mass is subjected to fairly intense movement, such as pumping, conveying or recasting. It is preferred to use surfactants which are anion-active or nonionic in the alkaline range.
  • fillers may also be incorporated, for example inorganic or organic substances in powder, fiber or granulate form.
  • Mineral fibers, packings, wood waste or rubber granulates are mentioned by way of example.
  • the porous bodies obtained after complete setting and drying (approximately 5 days) show excellent strength properties. Their compressive strength amounts to between about 3 and 50 kp/cm 2 in dependence upon the particular unit weight.
  • the unit weight may be varied within wide limits through the quantity of hydrogen peroxide used and amounts to between about 50 and 1000 and preferably to between about 200 and 800 kg/m 3 .
  • the pores are uniformly distributed and have a uniform size of about 0.1 to 4 mm, preferably about 0.2 to 2mm.
  • the porous bodies produced in accordance with the invention may be used, for example, in the form of blocks bricks or panels as lightweight building materials and insulating materials, more especially in cases where fireproof materials are required. They are completely non-inflammable, unaffected by periodic freezing and do not give off any gases when heated. They do not require high material and manufacturing costs and show outstanding strength and limited brittleness. Since the foamed mass is cast in liquid form and sets cold, the process may be carried out in situ. It is possible, for example, to fill gaps and cavities. The mass is preferably cast in the form of a heat-insulating and sound-insulating layer.
  • anhydrite binder according to DIN 4208 (CaO-content: 1.2% by weight) and the particular quantity indicated in the Table of active substance are suspended in 250 ml of water. The dependence of the pH-value upon time is measured. Whereas the anhydrite suspension reaches a pH-value of 12 after only 4 seconds without the addition, addition of the substances indicated in the Table considerably delays reaching of the pH-value of 12. Phosphates are particularly effective.
  • a mixture is prepared from:
  • the components are suspended over a period of 10 minutes.
  • the suspension with a pH-value of approximately 6.5 is introduced into form work.
  • the mass begins to foam after about 2 minutes, grows to more than twice its original volume in 12 minutes and begins to set after 16 minutes with its volume intact.
  • the body formed has fine uniform pores and, after drying, has a compressive strength of 370 N/cm 2 and a density of 0.65 g/cc.
  • H 2 O 2 50 ml of H 2 O 2 (35%) are added over a period of 30 seconds during mixing (10 minutes).
  • the foaming mass is introduced into a mold with a pH-value of about 12, grows for 30 seconds and hardens quickly with a heat effect.
  • the body formed has a density of 0.7 g/cc, is permeated by fractures and can be readily crushed by hand. On account of the inhomogeneous structure and limited mechanical strength, it was not possible to determine any values.
  • a mixture is prepared from:
  • the components are mixed over a period of 3 minutes and introduced into a mold in the form of a suspension with a pH-value of 7.
  • the mass begins to grow after a few minutes, its growth being complete after about 8 to 9 minutes.
  • a pH-value of 9 is reached after 5 minutes.
  • the set body shows a homogeneous fine pore structure and has a compressive strength of 265 N/cm 2 and a unit weight of 590 kg/m 3 .
  • the components are mixed over a period of about 30 seconds.
  • the foaming mixture is then introduced into a mold with a pH-value of 12. Growth lasts 1 minute 50 seconds.
  • the body formed has a unit weight of 730 kg/m 3 and a compressive strength of 134 N/cm 2 , i.e. by comparison with Example 3 30% more unit weight and only 50% of the strength value.
  • plasticizer maleic acid anhydride-styrene copolymer
  • the mixture fills about half the mold and grows uniformly over a period of 25 minutes up to the upper edge of the mold. A few minutes later it hardens.
  • the completed molding can be removed from the mold after 35 minutes.
  • the mold is coated with a mixture as described in Example 4.
  • the impregnated body 1 takes up about 66% less water than body 2 and quickly gives off the water taken up.
  • the components are mixed continuously in a vessel with a bottom outlet.
  • the suspension is transported through a vibrating chute at a controlled rate of 500 g/minute.
  • the metering of the solution is adjusted to 250 ml/minute through a second hose pump followed by a rotameter.
  • the binder used is a mixture of anhydrite binder and gypsum (70 parts of anhydrite and 30 parts of gypsum) to which a little MnO 2 is added as a decomposition catalyst.
  • the solution contains the following substances, based on 10 l of H 2 O:
  • the hardened foam body has a density of 0.45 g/cc following the removal by drying of excess water.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Catalysts (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
US05/604,868 1974-09-03 1975-08-14 Production of foamed gypsum moldings Expired - Lifetime US4043825A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE2442098A DE2442098A1 (de) 1974-09-03 1974-09-03 Verfahren zur herstellung poroeser koerper auf basis von gips, insbesondere anhydrit
DT2442098 1974-09-03

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US4043825A true US4043825A (en) 1977-08-23

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US (1) US4043825A (OSRAM)
JP (1) JPS5150934A (OSRAM)
BE (1) BE832899A (OSRAM)
DE (1) DE2442098A1 (OSRAM)
ES (1) ES440644A1 (OSRAM)
FR (1) FR2283872A1 (OSRAM)
GB (1) GB1511283A (OSRAM)
IE (1) IE41789B1 (OSRAM)
NL (1) NL7510411A (OSRAM)

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0040399A1 (en) * 1980-05-15 1981-11-25 Kurashiki Boseki Kabushiki Kaisha Foamed gypsum moulded articles and production thereof
US4523954A (en) * 1980-07-16 1985-06-18 Cdf Chimie, S.A. Process for manufacturing cellular plaster and molded plaster articles
US4652688A (en) * 1984-04-24 1987-03-24 The British Petroleum Company, P.L.C. Process for the production of hydrocarbons from hetero-substituted methanes
US5076978A (en) * 1987-09-14 1991-12-31 Blum Kurt E Method of producing gypsum decorative molding
US5173364A (en) * 1990-04-12 1992-12-22 Redco, N.V. Glass fibre reinforced plasterboard and a method for producing same
EP0814065A1 (de) * 1996-06-17 1997-12-29 Peroxid-Chemie GmbH Mittel und Verfahren zur Herstellung von Bindebaustoffen mit verminderter Dichte
WO1999008978A1 (en) * 1997-08-21 1999-02-25 United States Gypsum Company Method and composition for producing set gypsum-containing product with increased strength, rigidity, and dimensional stability
US6162839A (en) * 1995-12-20 2000-12-19 Henkel Kommanditgesellschaft Auf Aktien Composition for producing light plaster, production of the foaming agent used therefor and its use
US6342284B1 (en) 1997-08-21 2002-01-29 United States Gysum Company Gypsum-containing product having increased resistance to permanent deformation and method and composition for producing it
US6632550B1 (en) 1997-08-21 2003-10-14 United States Gypsum Company Gypsum-containing product having increased resistance to permanent deformation and method and composition for producing it
WO2007134349A1 (de) * 2006-05-19 2007-11-29 Manfred Sterrer Leichtbetone bzw. mineralschäume sowie verfahren zu ihrer herstellung
US9410058B2 (en) 2014-04-10 2016-08-09 United States Gypsum Company Compositions and methods for water-resistant gypsum fiber products

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5369441A (en) * 1976-12-01 1978-06-20 Nittetsu Kinzoku Kogyo Kk Massproducible sliding partition
RU2312845C1 (ru) * 2006-07-03 2007-12-20 Юлия Алексеевна Щепочкина Сырьевая смесь для производства ячеистых бетонов

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2662825A (en) * 1948-06-05 1953-12-15 Buffalo Electro Chem Co Refractory
US3688437A (en) * 1970-01-29 1972-09-05 Forenode Superfosfatfabrika Ab Pellets in the form of foamed bodies, and methods for the preparation thereof

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR862397A (fr) * 1938-12-29 1941-03-05 Gyproc Products Ltd Perfectionnements à l'aération des compositions de plâtre de paris
NL7307757A (OSRAM) * 1971-12-31 1973-12-11

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2662825A (en) * 1948-06-05 1953-12-15 Buffalo Electro Chem Co Refractory
US3688437A (en) * 1970-01-29 1972-09-05 Forenode Superfosfatfabrika Ab Pellets in the form of foamed bodies, and methods for the preparation thereof

Cited By (28)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4330589A (en) * 1980-05-15 1982-05-18 Kurashiki Boseki Kabushiki Kaisha Foamed gypsum moulded articles and production thereof
EP0040399A1 (en) * 1980-05-15 1981-11-25 Kurashiki Boseki Kabushiki Kaisha Foamed gypsum moulded articles and production thereof
US4523954A (en) * 1980-07-16 1985-06-18 Cdf Chimie, S.A. Process for manufacturing cellular plaster and molded plaster articles
US4652688A (en) * 1984-04-24 1987-03-24 The British Petroleum Company, P.L.C. Process for the production of hydrocarbons from hetero-substituted methanes
US5076978A (en) * 1987-09-14 1991-12-31 Blum Kurt E Method of producing gypsum decorative molding
US5173364A (en) * 1990-04-12 1992-12-22 Redco, N.V. Glass fibre reinforced plasterboard and a method for producing same
US5330691A (en) * 1990-04-12 1994-07-19 N.V. Recdo S.A. Method for producing glass fiber reinforced plasterboard
US6162839A (en) * 1995-12-20 2000-12-19 Henkel Kommanditgesellschaft Auf Aktien Composition for producing light plaster, production of the foaming agent used therefor and its use
EP0814065A1 (de) * 1996-06-17 1997-12-29 Peroxid-Chemie GmbH Mittel und Verfahren zur Herstellung von Bindebaustoffen mit verminderter Dichte
US7244304B2 (en) 1997-08-21 2007-07-17 United States Gypsum Company Gypsum-containing board and tile, and method for producing same
US20090047545A1 (en) * 1997-08-21 2009-02-19 United States Gypsum Company Gypsum-containing board and tile, and method for producing same
US6632550B1 (en) 1997-08-21 2003-10-14 United States Gypsum Company Gypsum-containing product having increased resistance to permanent deformation and method and composition for producing it
US6800131B2 (en) 1997-08-21 2004-10-05 United States Gypsum Company Gypsum-containing board and tile, and method for producing gypsum-containing board and tile
US20050019618A1 (en) * 1997-08-21 2005-01-27 United States Gypsum Company Gypsum-containing board and tile, and method for producing same
WO1999008978A1 (en) * 1997-08-21 1999-02-25 United States Gypsum Company Method and composition for producing set gypsum-containing product with increased strength, rigidity, and dimensional stability
US20070227405A1 (en) * 1997-08-21 2007-10-04 United States Gypsum Company Gypsum-containing board and tile, and method for producing same
US8974597B2 (en) 1997-08-21 2015-03-10 United States Gypsum Company Gypsum-containing product
US7425236B2 (en) 1997-08-21 2008-09-16 United States Gypsum Company Gypsum-containing board and tile, and method for producing same
US6342284B1 (en) 1997-08-21 2002-01-29 United States Gysum Company Gypsum-containing product having increased resistance to permanent deformation and method and composition for producing it
US7758980B2 (en) 1997-08-21 2010-07-20 United States Gypsum Company Gypsum-containing board and tile, and method for producing same
US20100273020A1 (en) * 1997-08-21 2010-10-28 United States Gypsum Company Gypsum-containing product and method for producing same
US20110132235A1 (en) * 1997-08-21 2011-06-09 United States Gypsum Company Gypsum-containing product and gypsum board
US7964034B2 (en) 1997-08-21 2011-06-21 United States Gypsum Company Gypsum-containing product and method for producing same
US8142914B2 (en) 1997-08-21 2012-03-27 United States Gypsum Company Gypsum-containing product and gypsum board
US8303709B2 (en) 1997-08-21 2012-11-06 United States Gypsum Company Gypsum-containing product
US8500904B2 (en) 1997-08-21 2013-08-06 United States Gypsum Company Gypsum-containing product
WO2007134349A1 (de) * 2006-05-19 2007-11-29 Manfred Sterrer Leichtbetone bzw. mineralschäume sowie verfahren zu ihrer herstellung
US9410058B2 (en) 2014-04-10 2016-08-09 United States Gypsum Company Compositions and methods for water-resistant gypsum fiber products

Also Published As

Publication number Publication date
JPS5150934A (OSRAM) 1976-05-06
IE41789L (en) 1976-03-03
DE2442098A1 (de) 1976-03-18
FR2283872B1 (OSRAM) 1979-06-22
IE41789B1 (en) 1980-03-26
BE832899A (fr) 1976-03-01
NL7510411A (nl) 1976-03-05
GB1511283A (en) 1978-05-17
ES440644A1 (es) 1977-06-01
FR2283872A1 (fr) 1976-04-02

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